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SERVICE BULLETIN Part No.

: M060279

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Manufacturing Deep Sea 5510: Insufficient Capacity
TECHNICAL DOCUMENT Protection Upgrade
Date 09/04/08

Application: All existing v8.xx DSE5510 controllers prior to v8.50.

Problem: When gensets utilising the Deep Sea Electronics (DSE) 5510 genset controller are
connected in parallel, with certain engine malfunctions e.g. fuel starvation, the
offending genset will be unable to maintain load and eventually drop in speed. Given
that the genset is in parallel with others, the net effect is for all sets to ‘follow’ the
drop in speed/frequency and ultimately all trip out on under speed. This is
particularly problematic for applications where 100% redundancy is provided by use
of multiple sets in parallel where a failure in a single set negates the advantages
provided by the provision of multiple sets.

Cause: The cause of this problem is inherent to all Deep Sea firmware versions prior to
v8.50.

Solution: With DSE5510 firmware v8.50, DSE have developed a protective feature that is
activated when the maximum governor trim capacity is reached, after a user
configurable delay the protective action is triggered.

Note: at the time of publication, this feature is only configurable via the controller
front panel editor. Future releases of the 5xxx PC utility software will eventually
include the facility to configure via the controller configuration tool.

Procedures to be followed;
• Responsibility. (page2)
• Equipment required. (page2)
• Procedure. (page2)
• Firmware. (page4)
• Enable protection. (page7)

Actions: Aggreko fleet to coordinate the upgrade of all effected units utilising Aggreko
personnel.

Rework by: Aggreko personnel.

Costs: Costs associated with modification – labour 30mins per controller.


If required the In-system connection lead is available from Aggreko Manufacturing,
order via part no. 11-0013413.
Warranty code WC/2008/003 will apply, please quote this number on all
correspondence.
Hire Fleet to confirm modification against each Plant Number to Aggreko
Manufacturing using the ARC failure report illustrated on page 8.

Key Contacts: Stephen Doherty, Controls Engineer, Aggreko Manufacturing


David McDonald, Development Engineer, Aggreko Manufacturing
Prepared By: D.McDonald Approved By: J.A.Casey / S.Doherty
CLP0317A (19/06)
SERVICE BULLETIN Part No.: M060279

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Manufacturing Deep Sea 5510: Insufficient Capacity
TECHNICAL DOCUMENT Protection Upgrade
Date 09/04/08

Responsibility
Persons carrying out the work described herein must do so in compliance with company safety
procedures and in a suitable work area. It is the responsibility of the individual carrying out the work to
ensure that all modifications are correctly incorporated.

Equipment Required
1. 1 off RJ45 Cat5 Ethernet patch cable ~ 1m *
2. 1 off female to female 9 way D-sub connector serial cable ~ 1m *
3. 5-way 5A terminal block *
4. Continuity tester or suitable electrical meter
5. Laptop computer c/w male 9 way D-sub serial connection com port
6. Firmware download software tool “SoftwareDownload5510.exe”

*Alternatively a pre-assembled communication lead is available via Manufacturing (Part No. 11-
0013413) quoting associated warranty code.

Procedure

In-system Cable Fabrication (Alternatively Order Part No. 11-0013413)


In order to download firmware to the controller, an in-system cable is required. This is not a standard
stock item and must be manually fabricated.

1. Cut the Cat5 and serial cables in half, take one of each halves and bare the insulation from the
non connector ends to expose approximately 50mm of the internal cores (remove any shielding
or protective covering).
2. Using a continuity tester or suitable electrical meter, determine the pin to core relationship of
the serial cable. e.g.

9 way D-sub Serial cable core


connector pin # colour
1 Green
2 Yellow
3 Orange
4 Black
5 Brown
6 n/c
7 Red
8 Blue
9 n/c
Note: The above colours are an example only, these
will vary from supplier to supplier of serial cable.

Prepared By: D.McDonald Approved By: J.A.Casey / S.Doherty


CLP0317A (19/06)
SERVICE BULLETIN Part No.: M060279

Page 3 of 8
Manufacturing Deep Sea 5510: Insufficient Capacity
TECHNICAL DOCUMENT Protection Upgrade
Date 09/04/08

3. Visually inspect or use a continuity tester to determine the pin to core relationship of the Cat5
cable. e.g.

Note: The above colours are an example only, these


will vary from supplier to supplier of Cat5 cable.

Using 5-way terminal block; ferrule, crimp and connect the serial and
Cat5 cores as per the following table.

9 way D-sub RJ45 connector


connector pin # pin #
2 8
3 6
5 7
7 2
8 4
Note: The cores/pins not listed above should be
discarded.

Prepared By: D.McDonald Approved By: J.A.Casey / S.Doherty


CLP0317A (19/06)
SERVICE BULLETIN Part No.: M060279

Page 4 of 8
Manufacturing Deep Sea 5510: Insufficient Capacity
TECHNICAL DOCUMENT Protection Upgrade
Date 09/04/08

Firmware Download
To complete the firmware upgrade, follow the instructions below;
1. Connect the in-system cable from the P810 port on the DSE5510 controller to the serial com
port on the laptop. Note: laptop connection must be made to a male 9pin D-sub serial com port,
USB converters will not suffice.
2. Copy the “SoftwareDownload5510.exe” application to “C:\” on the laptop.

3. Create a shortcut to the “SoftwareDownload5510.exe” application by right clicking on the file


and selecting “Create Shortcut” from the menu.

Prepared By: D.McDonald Approved By: J.A.Casey / S.Doherty


CLP0317A (19/06)
SERVICE BULLETIN Part No.: M060279

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Manufacturing Deep Sea 5510: Insufficient Capacity
TECHNICAL DOCUMENT Protection Upgrade
Date 09/04/08

4. Copy the shortcut onto the desktop.

5. Right click the shortcut and select “Properties” from the menu.

6. Edit the ‘Target:’ field to read as above where “1” equals the com port number to which the
DSE5510 is connected via the in-system cable. Ensure there is a space left between ‘exe’ and
the number ‘1’.

Prepared By: D.McDonald Approved By: J.A.Casey / S.Doherty


CLP0317A (19/06)
SERVICE BULLETIN Part No.: M060279

Page 6 of 8
Manufacturing Deep Sea 5510: Insufficient Capacity
TECHNICAL DOCUMENT Protection Upgrade
Date 09/04/08

7. To begin firmware download double-click the Software Dowload5510 shortcut on the desktop,
ensure all connections are in place and the DSE5510 is powered OFF.
8. Select ‘Start Download’.

9. Turn power ON to the DSE5510 within 30 seconds (if delayed longer download attempt will
timeout).
10. The controller display will read “Transferring Do Not Remove Power” and the four user
LED’s will cycle during the download process and the image below will be displayed on the
laptop. This should take approximately forty five seconds.

11. Once download is complete the new power-up display will show the upgraded firmware version
of v8.50. Click ‘OK’ to complete download process.

Prepared By: D.McDonald Approved By: J.A.Casey / S.Doherty


CLP0317A (19/06)
SERVICE BULLETIN Part No.: M060279

Page 7 of 8
Manufacturing Deep Sea 5510: Insufficient Capacity
TECHNICAL DOCUMENT Protection Upgrade
Date 09/04/08

Enable Protection
By default, the “Insufficient Capacity” protection is disabled. To enable and configure the protection
follow the instructions below;
1. With the genset at rest and the 5510 controller powered ON, access the front panel
configuration editor by pressing both the [ INFO ] and [ STOP ] buttons together.
2. Enter Password ‘2000’.
3. From the “Configuration” screen press the [ - ] once to access the “Insufficient
Capacity Action” menu.
4. Press the [ AUTO ] button once to edit the action of the Insufficient Capacity feature, by default
the action is set to ‘None’. Using the [ - ] or [ + ] buttons, scroll through the available actions and
select “Shutdown”. Press the [ AUTO ] button once to accept changes.
5. Press the [ - ] once to access the “Insufficient Capacity Delay” menu.
6. Press the [ AUTO ] button once to edit the delay of the Insufficient Capacity feature, by default
the delay is set to ’00:00’. Use the [ - ] or [ + ] buttons to set the delay to ’00:01’. Press the
[ AUTO ] button once to accept changes.
7. Press the [ STOP ] button once to exit the front panel configuration editor.

Prepared By: D.McDonald Approved By: J.A.Casey / S.Doherty


CLP0317A (19/06)
SERVICE BULLETIN Part No.: M060279

Page 8 of 8
Manufacturing Deep Sea 5510: Insufficient Capacity
TECHNICAL DOCUMENT Protection Upgrade
Date 09/04/08

Service Bulletin Confirmations to Manufacturing

Local Reporting Processes such as ARC Retrofit Confirmations must continue to be


completed in addition to this report.
This report is used by Manufacturing as confirmation for Warranty claims.

To confirm to manufacturing that service bulletins have been completed, the following should be completed:

1. Submit ARC Failure report as follows:


• Open ARC
• Select FUNCTIONS
• Select MANUFACTURING

You will be presented with the screen shown below.

• Under FORMS, select appropriate FAILURE REPORT.


• complete the failure report with the equipment details
• in the failure description box, complete the following
o M06XXXX completed
o Detail if unit has no issue or if a correction was necessary.

By submitting the failure report, this will be emailed to Manufacturing as a bulletin confirmation.

Prepared By: D.McDonald Approved By: J.A.Casey / S.Doherty


CLP0317A (19/06)